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| United States Patent |
6,132,150
|
|
Gaydos
|
October 17, 2000
|
Three-dimensional apparatus for a router for producing copies variations
of templates
Abstract
A three-dimensional apparatus for a router for positioning and guiding the
router to produce, from a workpiece, at least one of a substantial
duplicate of a three-dimensional configuration of a template and a
substantial variation of such three-dimensional configuration of such
template by routing such workpiece. The three-dimensional apparatus for a
router including a workpiece mounting platform for mounting the workpiece,
a template mounting platform for mounting the template, a router mounting
platform for mounting the router, a router positioning mechanism for
positioning the router mounting platform adjacent to the workpiece
mounting platform, a probe for tracing the three-dimensional configuration
of the template and a linkage interconnecting the probe and the router
mounting platform to move the router mounting platform in response to
movement of the probe. The router positioning mechanism including a
three-dimensional movement mechanism for permitting movement of the router
mounting platform in each of three mutually orthogonal directions.
| Inventors:
|
Gaydos; George G. (509 Peebles St., Apartment 3, Pittsburgh, PA 15221)
|
| Appl. No.:
|
206648 |
| Filed:
|
December 7, 1998 |
| Current U.S. Class: |
409/124; 409/93; 409/109 |
| Intern'l Class: |
B23C 001/18 |
| Field of Search: |
409/86,90,93,109,124,126,130,125
|
References Cited
U.S. Patent Documents
| 477229 | Jun., 1892 | Rohlmann | 83/818.
|
| 571535 | Nov., 1896 | Lochman | 409/111.
|
| 701903 | Jun., 1902 | Lochman | 409/93.
|
| 1721015 | Jul., 1929 | Galbraith | 409/108.
|
| 2018763 | Oct., 1935 | Kirby | 90/13.
|
| 2093009 | Sep., 1937 | Galbraith | 90/13.
|
| 2796095 | Jun., 1957 | Joseph | 144/291.
|
| 3171207 | Mar., 1965 | Wormser | 33/23.
|
| 3211061 | Oct., 1965 | Cretsinger | 90/13.
|
| 3301287 | Jan., 1967 | Edwards | 144/144.
|
| 3434385 | Mar., 1969 | Ray | 90/13.
|
| 3453933 | Jul., 1969 | Kornhauser | 90/13.
|
| 4095633 | Jun., 1978 | Kimball et al. | 144/144.
|
| 4098170 | Jul., 1978 | Russell | 90/13.
|
| 4183284 | Jan., 1980 | Laskowski | 90/13.
|
| 4227557 | Oct., 1980 | Allen | 142/7.
|
| 4278117 | Jul., 1981 | Mitchell et al. | 144/144.
|
| 4300863 | Nov., 1981 | Partain | 409/109.
|
| 4364695 | Dec., 1982 | Lenz | 409/103.
|
| 5569004 | Oct., 1996 | Marantette | 409/235.
|
| 5993123 | Nov., 1999 | Allred, III et al. | 409/109.
|
Primary Examiner: Gerrity; Stephen F.
Assistant Examiner: Wilson; Adrian M.
Attorney, Agent or Firm: James Ray & Associates
Claims
I claim:
1. A three-dimensional apparatus for a router for positioning and guiding
the router to produce, from a workpiece, at least one of a substantial
duplicate of a three-dimensional configuration of a template and a
substantial variation of such three-dimensional configuration of such
template by routing such workpiece, said three-dimensional apparatus for a
router comprising:
a workpiece mounting platform for mounting such workpiece;
a template mounting platform for mounting such template;
a router mounting platform for mounting such router;
a router positioning mechanism for positioning said router mounting
platform adjacent to said workpiece mounting platform;
a probe for tracing such three-dimensional configuration of such template;
and
a linkage interconnecting said probe and said router mounting platform to
move said router mounting platform in response to movement of said probe;
said router positioning mechanism comprising three-dimensional movement
means for permitting movement of said router mounting platform in each of
three mutually orthogonal directions;
said three mutually orthogonal directions comprising a substantially
vertical direction, a first substantially horizontal direction and a
second substantially horizontal direction;
said router positioning mechanism comprising a suspension mechanism for
suspending said router mounting platform substantially vertically above
said workpiece mounting platform;
said suspension mechanism comprising:
a vertical translation mechanism for simultaneously moving said probe and
said router mounting platform in said substantially vertical direction;
a first horizontal translation mechanism for simultaneously moving said
probe and said router mounting platform in said first substantially
horizontal direction; and
a second horizontal translation mechanism for simultaneously moving said
probe and said router mounting platform in said second horizontal
direction;
said vertical translation mechanism comprising at least one vertical shaft
and at least one vertical bearing engaging said at least one vertical
shaft;
said first horizontal translation mechanism comprising at least one first
horizontal shaft and at least one first horizontal bearing engaging said
at least one first horizontal shaft; and
said second horizontal translation mechanism comprising at least one second
horizontal shaft and at least one second horizontal bearing engaging said
at least one second horizontal shaft, said at least one second horizontal
shaft being disposed at substantially a right angle with respect to said
at least one first horizontal shaft.
2. A three-dimensional apparatus for a router, according to claim 1,
wherein said three-dimensional apparatus for a router additionally
comprises counterbalancing means for counterbalancing a substantial
portion of a weight of said router mounting platform and such router when
such router is mounted on said router mounting platform, such weight
acting in said substantially vertical direction.
3. A three-dimensional apparatus for a router, according to claim 2,
wherein said counterbalancing means includes a biasing element urging said
router mounting platform in a substantially upward direction away from
said workpiece mounting platform and substantially parallel to said
substantially vertical direction.
4. A three-dimensional apparatus for a router, according to claim 3,
wherein said linkage interconnecting said probe and said router mounting
platform includes a substantially rigid member interconnecting said probe
and said router mounting platform.
5. A three-dimensional apparatus for a router, according to claim 4,
wherein said linkage interconnecting said probe and said router mounting
platform comprises an offset arm, said offset arm projecting outward from
said router mounting platform, said probe being mounted on said offset arm
and extending toward said template mounting platform.
6. A three-dimensional apparatus for a router for positioning and guiding
the router to produce, from a workpiece, at least one of a substantial
duplicate of a three-dimensional configuration of a template and a
substantial variation of such three-dimensional configuration of such
template by routing such workpiece, said three-dimensional apparatus for a
router comprising:
a workpiece mounting platform for mounting such workpiece;
a template mounting platform for mounting such template;
a router mounting platform for mounting such router;
a router positioning mechanism for positioning said router mounting
platform adjacent to said workpiece mounting platform;
a probe for tracing such three-dimensional configuration of such template;
and
a linkage interconnecting said probe and said router mounting platform to
move said router mounting platform in response to movement of said probe;
said router positioning mechanism comprising three-dimensional movement
means for permitting movement of said router mounting platform in each of
three mutually orthogonal directions;
said three mutually orthogonal directions comprising a substantially
vertical direction, a first substantially horizontal direction and a
second substantially horizontal direction, and said router positioning
mechanism comprising a suspension mechanism for suspending said router
mounting platform substantially vertically above said workpiece mounting
platform;
wherein said three-dimensional apparatus for a router additionally
comprises counterbalancing means for counterbalancing a substantial
portion of a weight of said router mounting platform and such router when
such router is mounted on said router mounting platform, such weight
acting in said substantially vertical direction;
wherein said counterbalancing means comprises a biasing element urging said
router mounting platform in a substantially upward direction, away from
said workpiece mounting platform and substantially parallel to said
substantially vertical direction;
wherein said linkage interconnecting said probe and said router mounting
platform comprises a substantially rigid member interconnecting said probe
and said router mounting platform;
wherein said linkage interconnecting said probe and said router mounting
platform comprises an offset arm, said offset arm projecting outward from
said router mounting platform, said probe being mounted on said offset arm
and extending toward said template mounting platform;
wherein said suspension mechanism comprises:
a vertical translation mechanism for simultaneously moving said probe and
said router mounting platform in said substantially vertical direction;
a first horizontal translation mechanism for simultaneously moving said
probe and said router mounting platform in said first substantially
horizontal direction; and
a second horizontal translation mechanism for simultaneously moving said
probe and said router mounting platform in said second horizontal
direction; and
wherein said vertical translation mechanism comprises at least one vertical
shaft and at least one vertical bearing engaging said at least one
vertical shaft, wherein said first horizontal translation mechanism
comprises at least one first horizontal shaft and at least one first
horizontal bearing engaging said at least one first horizontal shaft and
wherein said second horizontal translation mechanism comprises at least
one second horizontal shaft and at least one second horizontal bearing
engaging said at least one second horizontal shaft, said at least one
second horizontal shaft being disposed at substantially a right angle with
respect to said at least one first horizontal shaft.
7. A three-dimensional apparatus for a router, according to claim 6,
wherein said vertical translation mechanism includes a plurality of
vertical shafts and a plurality of vertical bearings, at least one each of
said plurality of vertical bearings engaging one each of said plurality of
vertical shafts.
8. A three-dimensional apparatus for a router, according to claim 7,
wherein said first horizontal translation mechanism includes a first
plurality of horizontal shafts and a first plurality of horizontal
bearings, at least one each of said first plurality of horizontal bearings
engaging one each of said first plurality of horizontal shafts.
9. A three-dimensional apparatus for a router, according to claim 8,
wherein said second horizontal translation mechanism includes a second
plurality of horizontal shafts, said second plurality of horizontal shafts
being disposed at substantially right angles with respect to said first
plurality of horizontal shafts, and a second plurality of horizontal
bearings, at least one each of said second plurality of horizontal
bearings engaging one each of said second plurality of horizontal shafts.
10. A three-dimensional apparatus for a router, according to claim 11,
wherein at least one each of said vertical bearings slidingly engage one
each of said first plurality of vertical shafts, wherein at least one each
of said first plurality of horizontal bearings slidingly engage one each
of said first plurality of horizontal shafts and wherein at least one each
of said second plurality of horizontal bearings slidingly engage one each
of said second plurality of horizontal shafts.
11. A three-dimensional apparatus for a router, according to claim 10,
wherein said three-dimensional apparatus for a router additionally
includes a second template mounting platform, a second probe and an
additional offset arm projecting outward from said router mounting
platform, said second probe being mounted on said second offset arm and
extending toward said second template mounting platform and said first and
second template mounting platforms being disposed on opposite sides of
said workpiece mounting platform.
12. A three-dimensional apparatus for a router, according to claim 11, said
three-dimensional apparatus for a router additionally includes a frame
portion and a vertically translatable subassembly, said vertically
translatable subassembly including:
said router mounting platform;
said first horizontal translation mechanism; and
said second horizontal translation mechanism;
said vertical translation mechanism being operative to permit movement of
said vertically translatable subassembly in said substantially vertical
direction with respect to said frame portion;
and wherein said biasing element includes an elongated elastic member.
13. A three-dimensional apparatus for a router, according to claim 12, said
three-dimensional apparatus for a router additionally includes a support
member disposed above said vertically translatable subassembly, said
elongated elastic member having two opposing ends, said two opposing ends
of said elongated elastic member being connected to said vertically
translatable subassembly and said elongated elastic member extending over
said support member.
14. A three-dimensional apparatus for a router, according to claim 13,
wherein said support member includes at least one pulley.
15. A three-dimensional apparatus for a router, according to claim 14,
wherein said at least one pulley includes at least two pulleys, said at
least two pulleys being disposed on opposing sides of said router mounting
platform and each of said at least two pulleys being disposed outward of
said router mounting platform.
16. A three-dimensional apparatus for a router, according to claim 15,
wherein said first plurality of vertical shafts includes four vertical
shafts, said first plurality of vertical bearings includes at least four
vertical bearings, one each of said at least four vertical bearings
slidingly engages one each of said four vertical shafts, said vertically
translatable subassembly additionally includes said at least four vertical
bearings and each of said at least four vertical bearings includes a slide
block bearing slidingly engaging one of said four vertical shafts.
17. A three-dimensional apparatus for a router, according to claim 16,
wherein said vertically translatable subassembly additionally includes a
pair of end plates, a first of said pair of end plates extending
substantially between a first two of said at least four vertical bearings,
a second of said pair of end plates extending substantially between a
second two of said at least four vertical bearings, wherein one each of
said two opposing ends of said elongated elastic member are connected to
one each of said pair of end plates and wherein said elongated elastic
member includes an elongated coil spring member.
18. A three-dimensional apparatus for a router, according to claim 17:
wherein said at least four vertical bearings includes six vertical
bearings, a first pair of said six vertical bearings being vertically
spaced from one another and slidingly engaging a first of said four
vertical shafts, a second pair of said six vertical bearings being
vertically spaced from one another and slidingly engaging a second of said
four vertical shafts and one each of said six vertical bearings slidingly
engaging one each of a third and fourth of said four vertical shafts;
wherein each of said first plurality of horizontal bearings includes a
slide block bearing slidingly engaging one of said first plurality of
horizontal shafts and each of said second plurality of horizontal bearings
includes a slide block bearing slidingly engaging one of said second
plurality of horizontal shafts;
wherein said second plurality of horizontal bearings includes at least two
horizontal bearings slidingly engaging a first of said second plurality of
horizontal shafts and at least an additional two horizontal bearings
slidingly engaging a second of said second plurality of horizontal shafts;
wherein said offset arm and said additional offset arm extend outward
substantially along a single line from said router mounting platform;
wherein said frame includes a base member, said four vertical shafts are
connected to and extend upward from said base member;
wherein said three-dimensional apparatus for a router additionally includes
a pair of cross members, one each of said pair of cross members extending
between two of said four vertical shafts, one each of said at least two
pulleys being mounted on one each of said pair of cross members and said
coil spring member extending over said at least two pulleys and transverse
to said single line of said offset arm and said additional offset arm;
wherein said workpiece mounting platform includes a workpiece clamping
mechanism for clamping such workpiece to said base member, said template
mounting platform includes a template clamping mechanism for clamping such
template to said base member, said second template mounting platform
includes a second template clamping mechanism for clamping another such
template to said base member and wherein said router mounting platform
includes a router attachment means for securing such router to said router
mounting platform;
wherein each of said end plates of said vertically translatable subassembly
is connected to three of said six vertical bearings;
wherein said three-dimensional apparatus for a router additionally includes
a handle extending upward from said offset arm on an opposite side of said
offset arm from said probe, an additional handle extending upward from
said additional offset arm on an opposite side of said additional offset
arm from said second probe, a bolster disposed at the intersection of each
of said four vertical shafts and said base member and a pair of strap
members, one each of said pair of strap members extending between pairs of
said vertical shafts and said strap members extending substantially
parallel to said coil spring;
wherein said vertically translatable subassembly has an upward limit of
travel position wherein one each of said first pair and said second pair
of said vertical bearings contacts one of said pair of strap members; and
wherein said vertically translatable subassembly has a downward limit of
travel position wherein one each of said first pair and said second pair
of said vertical bearings contacts one of bolsters.
19. A three-dimensional duplicating milling apparatus for mounting a
milling tool and for producing, in a workpiece, at least one of a
substantial reproduction of a template and a substantial variation of such
template, such template extending along three separate and independent
axes, said milling apparatus comprising:
at least one template platform for mounting such template in a template
position;
a workpiece platform for mounting such workpiece in a workpiece position;
a milling tool support structure for mounting such milling tool in a
milling tool position;
probe means for determining a surface of such workpiece with respect to
said workpiece position; and
linkage means for determining said milling tool position in response to
said determined surface of such workpiece;
such template having three separate and independent axes; and
said linkage means being effective to alter said milling tool position in
each of said three separate and independent axes with respect to a
position of said probe;
said linkage means comprising:
a vertical translation mechanism comprising at least one vertical shaft and
at least one vertical bearing engaging said at least one vertical shaft;
a first horizontal translation mechanism comprising at least one first
horizontal shaft and at least one first horizontal bearing engaging said
at least one first horizontal shaft; and
a second horizontal translation mechanism comprising at least one second
horizontal shaft and at least one second horizontal bearing engaging said
at least one second horizontal shaft.
20. A three-dimensional duplicating milking apparatus, according to claim
19, wherein said at least one second horizontal shaft is disposed at
substantially a right angle with respect to said at least one first
horizontal shaft.
21. A three-dimensional apparatus for a router, according to claim 20,
wherein:
said at least one vertical bearing comprises a plurality of vertical
bearings engaging said at least one vertical shaft;
said at least one first horizontal bearing comprises a plurality of first
horizontal bearings engaging said at least one first horizontal shaft;
said at least one second horizontal bearing comprises a plurality of second
horizontal bearings engaging said at least one second horizontal shaft.
22. A three-dimensional apparatus for a router, according to claim 21,
wherein:
said plurality of vertical bearings comprises at least two vertical
bearings engaging said at least one vertical shaft;
said plurality of first horizontal bearings comprises at least two first
horizontal bearings engaging said at least one first horizontal shaft; and
said plurality of second horizontal bearings comprises at least four second
horizontal bearings engaging said at least one second horizontal shaft.
Description
FIELD OF THE INVENTION
The present invention relates, in general, to woodworking equipment and,
more particularly, this invention relates to an apparatus for use with a
widely available router to permit the router to readily and accurately
duplicate a three-dimensional contour of an object, for example, a
template.
BACKGROUND OF THE INVENTION
As is generally well known in the prior art, routers are in widespread use
among carpenters, craftspeople and generally anyone involved in
woodworking.
Frequently, a craftsperson (e.g., a woodworker) wishes to duplicate a
contour of an existing object so as to reproduce any of a number of
already existing decorative or utilitarian designs in wood and/or other
materials.
Alternatively, a craftsperson may wish to produce repeated copies of a
particular three-dimensional design which may be embodied in a template.
OBJECTS OF THE INVENTION
It is, therefore, one of the primary objects of the present invention to
provide a three-dimensional apparatus for a router which allows the router
to be utilized in a manner that will enable a more accurate reproduction
of a three-dimensional contour of an existing object, for example, a
template or an already existing design.
Another object of the present invention is to provide a three-dimensional
apparatus which allows the router to produce, working from an existing
template, three-dimensional designs in a workpiece which are substantial
variations on the three-dimensional design embodied in the template.
A further object of the present invention is to provide an apparatus which
is relatively simple in design and rather rugged in construction and,
therefore, inexpensive to manufacture and durable in use.
In addition to the objects and advantages of the present invention
described above, various other objects and advantages of the invention
will become more readily apparent to those persons skilled in the relevant
art from the following more detailed description of the invention,
particularly, when such description is taken in conjunction with the
attached drawing Figures and with the appended claims.
SUMMARY OF THE INVENTION
In one aspect, the invention features a three-dimensional apparatus for a
router for positioning and guiding a router to produce, from a workpiece,
at least one of a substantial duplicate of a three-dimensional
configuration of a template and a substantial variation of such
three-dimensional configuration of such template by routing a workpiece.
The three-dimensional apparatus for a router includes a workpiece mounting
platform for mounting the workpiece, a template mounting platform for
mounting the template, a router mounting platform for mounting the router
and a router positioning mechanism for positioning the router mounting
platform adjacent the workpiece mounting platform. A probe is provided for
tracing the three-dimensional configuration of the template and a linkage
interconnects the probe and the router mounting platform to move the
router mounting platform in response to movement of the probe. The router
positioning mechanism includes a three-dimensional movement mechanism for
permitting movement of the router mounting platform in each of three
mutually orthogonal directions.
In another aspect, the invention generally features a three-dimensional
milling apparatus for mounting a milling tool and for producing, in a
workpiece, at least one of a substantial reproduction of a template and a
substantial variation of the template when the template extends along
three separate and independent axes. The milling apparatus includes at
least one template platform for mounting the template in a template
position, a workpiece platform for mounting the workpiece in a workpiece
position and a milling tool support structure for mounting the milling
tool in a milling tool position. A probe is provided for determining a
surface of the workpiece with respect to the workpiece position and a
linkage mechanism determines the milling tool position in response to the
determined surface of the workpiece. The template has three separate and
independent axes and the linkage means is effective to alter the milling
tool position in each of the three separate and independent axes with
respect to a position of the probe.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of a particular preferred
embodiment, reference being made to the attached drawings, wherein:
FIG. 1 is frontal perspective of a three-dimensional apparatus for a router
according to a presently preferred embodiment of the invention;
FIG. 2 is a sectional elevational view of the inventive router apparatus
taken along the lines shown as 2--2 in FIG. 1; and
FIG. 3 is a detailed elevational view of a portion of FIG. 1, showing in
detail a slide block bearing employed in the preferred embodiment of the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Prior to proceeding to the more detailed description of the invention, it
should be noted that identical components having identical functions have
been identified with identical reference numerals throughout the several
views illustrated in the drawing Figures.
Referring to FIGS. 1 and 2, a router apparatus adapted for the reproduction
of a three-dimensional contour of an object is generally designated by
reference numeral 10. An object which already embodies the
three-dimensional contour which it is desired to duplicate is generally
referred to herein as a "template" and is indicated by reference numeral
12.
While the term "template" is used herein, such term should not be
understood to limit the invention to the reproduction only of so-called
templates. The invention can be readily used to reproduce a
three-dimensional contour of a wide range of existing objects, for
example, to duplicate a molding or filigree design in carpentry, etc.
The design is to be duplicated from the template 12 into a workpiece 14,
the work being performed by a router, the router being shown generally in
phantom and designated by reference numeral 16.
The router apparatus 10 generally includes a workpiece mounting platform 18
for mounting the workpiece 14, a template mounting platform 20 for
mounting the template 12 and a router mounting platform 22 for mounting
the router 16. The router 16 is positioned adjacent the workpiece 14 and,
preferably, is suspended over the workpiece 14 by a router positioning
mechanism 24.
As will be explained more fully below, the router positioning mechanism 24,
in combination with a counterbalancing mechanism described herein, is
effective to permit the router mounting platform 22 and the router 16
mounted thereon to be moved simultaneously through three mutually
orthogonal axes, e.g., the x, y and z axes, while additionally supporting
the weight of the router mounting platform 22 and the router 16 mounted
thereupon, thereby relieving the operator of the router apparatus 10 from
supporting such combined weight and allowing for a more controlled and
dexterous sculpting of the workpiece 14.
A probe 26 is provided for contacting and tracing (i.e., moving over) a
three-dimensional contour of the workpiece 14 and a linkage mechanism
connects the probe 26 to the router mounting platform 22 so as to cause
the router mounting platform 22 to move in response to movement of the
probe 26 as it traces the three-dimensional contour of the workpiece 14.
Preferably, as shown in FIGS. 1 and 2, such a linkage mechanism is
provided in the form of a rigid offset arm 28 which extends outward from
the router mounting platform 22. Additionally, in order to allow for a
rapid switching between different templates, the router apparatus 10
preferably includes a second template mounting platform 30 and a second
probe 32 positioned thereover by an additional offset arm 34 extending
outward from the router mounting platform 22.
The router positioning mechanism 24 permits simultaneous movement of the
router mounting platform 22 in three different directions by providing a
vertical translation mechanism 36, a first horizontal translation
mechanism 38 and a second horizontal translation mechanism 40. The first
horizontal translation mechanism 38 and the second horizontal translation
mechanism 40 permit movement of the router mounting platform 22 along
horizontal axes which are substantially perpendicular to one another and
the vertical translation mechanism 36 provides movement of the router
platform 22 along an axis which is substantially perpendicular to both of
the horizontal movement axes provided by the first and second horizontal
translation mechanisms 38 and 40.
Thus, it should be readily apparent that the presently preferred router
positioning mechanism 24 permits substantially simultaneous movement of
the router mounting platform 22 in each of these three mutually orthogonal
directions, i.e., a vertical direction and two mutually perpendicular
horizontal directions.
The vertical, first horizontal and second horizontal translation mechanisms
36, 38 and 40, respectively, are preferably provided as slide block
bearing assemblies. To this end, the router apparatus 10 includes a base
member 46 of generally oblong shape and having four vertical shafts 48
projecting vertically upward from the four corners thereof. Such router
mounting platform 22 is mounted on a vertically translatable subassembly
50 which includes the router mounting platform 22, the first and second
horizontal translation mechanisms 38 and 40 and at least four vertical
bearings 52.
One each of the four vertical bearings 52 slidingly engages one each of the
four vertical shafts 48, thereby permitting the vertically translatable
subassembly 50 to move vertically with respect to the base member 46 and
the four vertical shafts 48. Preferably, the vertical bearings 52 are
provided as slide block bearings which substantially surround and
slidingly engage the vertical shafts 48.
In order to implement the first horizontal translation mechanism 38, the
vertically translatable subassembly 50 further includes four bracket
members 54, one each of which extends outward from one each of the
vertical bearings 52 and a first set of horizontal shafts 56 which extend
between respective pairs of the bracket members 54 on opposite sides of
the workpiece mounting platform 18.
A first set of horizontal bearings 58 slidingly engage the first set of
horizontal shafts 56 to thereby permit the router mounting platform 22
(and the probe 26 linked thereto by the offset arm 28) to move in a first
horizontal direction with respect to the base member 46, with respect to
the workpiece mounting platform 18 and with respect to the template
mounting platform 20. The first set of horizontal bearings 58 are also
preferably provided in the form of slide block bearings which surround and
slidingly engage the first set of horizontal shafts 56.
The second horizontal translation mechanism 40 of the router positioning
mechanism 24 is preferably implemented by providing the router apparatus
10 with a second set of horizontal shafts 60 that are connected to the
first set of horizontal bearings 58 through a pair of flange members 62.
Each of the flange members 62 is connected to and extends horizontally
from one each of the first set of horizontal bearings 58 and the second
set of horizontal shafts 60 are aligned in parallel and extend at
substantially right angles to the first set of horizontal shafts 56. A
second set of horizontal bearings 64 slidingly engage the second set of
horizontal shafts 60 and the second set of horizontal bearings 64 are
connected, e.g., by welding or other suitable means, to the router
mounting platform 22. Again, preferably, the second set of horizontal
bearings 64 are of the slide block type.
In the presently preferred embodiment, the second set of horizontal shafts
60 are positioned vertically above the first set of horizontal shafts 56.
Through the provision of each of the vertical translation mechanism 36, the
first horizontal translation mechanism 38 and the second horizontal
translation mechanism 40 as described above, the router mounting platform
22 and the probe 26 linked thereto are enabled for simultaneous movement
in each of three mutually orthogonal directions.
Since commercially available routers may be of considerable weight and in
order to reduce the strain on the operator, the router apparatus 10
additionally preferably includes a counterbalancing mechanism 66 for
counterbalancing the combined weight of the router mounting platform 22
and any router 16 mounted thereon. Such counterbalancing mechanism
includes a biasing element 68 for resiliently urging the router mounting
platform 22 in an upwardly direction. Preferably, the biasing element 68
is provided in the form of an elongated coil spring 70. However, it will
be apparent that other elastic elements can be substituted therefor.
In addition, various placements and configurations of the biasing element
68 can be imagined. For example, the biasing element 68 could be
configured as an extensible coil spring surrounding any or all of the
vertical shafts 48 and connected to the vertically translatable
subassembly 50 so as to be put in tension under the weight of such
vertically translatable subassembly 50. Alternatively, the biasing element
68 could be configured as a compressible coil spring surrounding any or
all of the vertical shafts 48 and be positioned beneath the vertical
bearings 52 so as to be compressed by the weight of the vertically
translatable subassembly 50.
However, the present inventor has discovered that, in either of these or
similar configurations, the resulting upward force exerted by the biasing
element 68 is not as "linear" with respect to displacement as could be
desired. Further, it has been discovered that a configuration utilizing a
more elongated biasing element 68 produces a more desirable result.
To this end, the elongated coil spring 70 is extended over at least one,
and preferably two, supporting members 72 which are positioned above the
vertically translatable subassembly 50. The supporting members are
preferably provided as pulleys 74 which are rotatably mounted on cross
members, preferably in the form of spindles 76, extending between pairs of
the vertical shafts 48 on opposite sides of and outward of the router
mounting platform 22. The opposing ends of the elongated coil spring 70
are connected to a pair of end plates 78 which are, in turn, connected to
the vertically translatable subassembly by their attachment to the four
vertical bearings 52. The end plates 78, therefore, move with the
vertically translatable subassembly 50. In the presently preferred
embodiment, the ends of the coil spring 70 are provided with hooked
portions 79 which hook over the lower edges of the end plates 78.
It has been found preferable to utilize, in addition to the four vertical
bearings 52 already described, two additional vertical bearings 80 (also
preferably of the slide block type). Each of the two additional vertical
bearings 80 are slidably mounted on one of the four vertical shafts 48
above one of the four vertical bearings 52 and are vertically spaced
therefrom. Thus, preferably, there are three each of the vertical bearings
52 and 80 that are positioned on each flanking side of the router mounting
platform 22. A pair of longitudinal bars 82 run lengthwise connecting
pairs of the vertical shafts 48 and providing an upper travel limit when
the additional vertical bearings 80 contact the longitudinal bars 82.
Similarly, bolsters 84 are located at the bases of the vertical shafts 48
and adjacent the base member 46 to thereby limit the lower travel of the
vertically translatable subassembly 50 by the contact of the vertical
bearings 52 therewith.
A template clamping mechanism 86 is provided for clamping the template 12
to the template mounting platform 20. In the presently preferred
embodiment, the template clamping mechanism 86 is provided in the form of
four threaded template clamping screws 88. A workpiece clamping mechanism
90 is similarly provided for clamping the workpiece 14 to the workpiece
mounting platform 18, presently preferred as being in the form of four
threaded workpiece clamping screws 92.
Typically, a commercially available router has a base plate which is
provided with screw holes, etc. to allow the router to be attached to an
accessory such as a router table. The router mounting platform 22 is
preferably configured to mate with the base plates of such routers through
provision of appropriately placed screw holes 94, etc.
To allow the probe 26 to be conveniently traced over the three-dimensional
contour of the template 12, each of the offset arms 28 and 34 is provided
with an upstanding handle 96.
Preferably, the router 16 is of the so-called "plunge router" type, thereby
allowing the router bit to be plunged into the workpiece 14 until the
slack is removed from the plunge mechanism, whereupon the probe 26 is then
moved down into contact with the template 12.
FIG. 3 is a detailed enlarged view of a portion of FIG. 2, showing one of
the first set of horizontal bearings 58, the flange member 62 connected
thereto and one of the second set of horizontal shafts 60 extending from
the flange member 62. The horizontal bearings 58, as well as all of the
remaining slide block type bearings 52, 64 and 80, preferably include a
pillow block 98 and a "ball binding bearing" 100 positioned within the
pillow block, the ball binding bearing 100 sliding along the respective
shaft 48, 56 or 60.
Applicant has achieved good results utilizing for the pillow blocks 98,
ball binding bearings 100 and shafts 48, 56 and 60 the following
components obtained from Thompson Industries, Inc.:
Pillow Blocks: Part No. SPB16
Ball Binding Bearings: Part No. B162536
Shafts: ground and hardened
In operation, a template 12 positioned in either template mounting platform
20 or 30 may be substantially duplicated into a workpiece 14 positioned in
the workpiece mounting platform 18 by tracing the three-dimensional
contour of the template 12 with the respective probe 26 or 32. In order to
substantially duplicate the template, substantially the same or a similar
set of router bits are used as were originally used in producing the
template 12.
Additionally, however, the applicant has discovered that new and unusual
patterns can be produced by fitting the router 16 with a different
assortment of bits which vary from those used to produce the original
template. Accordingly, the present invention can also be utilized to
produce alternative and/or derivative designs by fitting the router 16
with different sets of bits.
While the present invention has been described by way of a detailed
description of a particularly preferred embodiment, it will be readily
apparent to those of ordinary skill in the art that various substitutions
of equivalents may be affected without departing from the spirit or scope
of the invention as set forth in the appended claims.
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